Design Review Report- Aluminum Alloy Wheel

Oct, 2008

By Zhao Guoyuan

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1.Wheel Design
2.Manufacture
Process
3.Test Method

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What can I
design ?

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a.

Brakes

Brake profile

b.

Valve Stem

Valve angles are typically 22 to 25

degrees

c.

Bolt Circle

Typical bolt circle diameters are 100,

114.3, and 127 millimeters. The number
of studs range from four to eight, but are
typically five .

d.

Tire

The rim section is key to the tire

interface. Tires must be easily assembled
onto the wheel using existing mounting
equipment in the assembly plants, and
must be easily serviced in the field.

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Wheel Alignment

What is wheel alignment and why is it

required?
Wheel alignment is the method in which the the
wheels of the vehicle are aligned in an optimum
condition that enhances directional stability, drive
comfort and steerability to the vehicle.
It is essential that the wheel alignment values are
checked as per the manufacturer`s
recommendations since an altered alignment could
lead to:
Uneven tyre wear
Unstable straight-ahead driving and steerability
Over and Under-steering of the vehicle

Alignment
parameters

Toe

Camber

Caster

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R&DR&D- Engineering
Engineering Tools
Tools

Design Software:

AutoCAD

Pro/E

UG

Catia

CAE

Finite-Element-Analysis of product structure. (I-DEAS ,Anysis)

Predict high stress areas

Computer simulation Analysis of Casting process. (MAGMA ,

Anycasting )

Used to verify mold/cooling design to predict possible problem

areas.

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Design Software Platform

UG
CATIA
ANSYS
AutoCAD

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Reverse
engineering
If the customer provide

samples for re-design. Supplier

can use laser scanner for reverse engineering.

Scanning data

3D data

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ABS Proto type model

Make the model (ABS, Nylon , Wooden ) based on 3D
data for Design Verification.

3D data

model

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Computer simulation
Casting Process
Simulated

Solidification Process

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Gravity VS Low pressure Casting

The major difference between gravity and low pressure
casting is the direction of the metal flow .

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Main
Main process
process flow
flow chart
chart

Melting

Casting

Heat- treat

Machining

Painting

Package

Melting

Casting

Solution

Machining

Powder

Low Point

Refining

X-Ray
Inspect

Aging

Leakage
Test

Color paint\

Packaging

Manufacturing Process

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Melting

Casting

A356

6.5-7.5%Si,0.12%Fe,0.10%Cu,0.306.5-7.5%Si,0.12%Fe,0.10%Cu,0.300.45%Mg,0.05%Mn,0.05Zn,0.20Ti,Others
0.45%Mg,0.05%Mn,0.05Zn,0.20Ti,OthersAlAl

Low
LowPressure
PressureCasting
Casting; ;Gravity
GravityCasting;
Casting;Tilt
TiltGravity
GravityCasting
Casting

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X-Ray Check

Heat Treat T6

100
100X-Ray
X-RayCheck
CheckAutomatic
AutomaticVS
VSManual
Manual

Improve
Improvemechanical
mechanicalproperties
propertiesand
andhardness
hardness
Control
temperature
deviation
+/-5C
Control temperature deviation +/-5C

Solution treat 545+/-5C ; Quench >70C, 5+/-1 Minute ; Aging 135+/-5C ..+/-minutes

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CNC Machining

Leak Test

Helium
HeliumLeak
LeakTest
Test

Leak Rate shall not exceed the rate of 0.5Psi per month

Water
WaterLeak
LeakTest
Test

>400Kpa , keep 30s

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Paint line

First harmonic low point tester

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Test
Test Lab-Material
Lab-Material Performance
Performance

Chemical composition
Tensile strength
Yield strength
Elongation
Hardness
Microstructure

A356 (T6)
Tensile strength=214MPa Min. Yield strength= 114MPa Min.
Elongation=7% Min.

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Test
Test Lab-Strength
Lab-Strength Test
Test
13/ 30 / 90 Impact test
Bending fatigue test
Radial fatigue test

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13o Impact
Test

Impact mass: 611N

Drop height:
2302mm
Tire: 215/65R16
Tire pressure: 200kPa

1 No Fracture penetrating through the wheel

disc.
2) The disc don't separate from the rim.
3) No air sudden leak ( full leakage in 1 minute ).

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Cornering Bending Test

Moment: 4032 Nm
Cycles: 200,000 times
Bolt Torque:
108 112 Nm

1) No deformation around the bolt holes.

2) No fatigue crack visible with dye penetrant
analysis.
3) The torque loosing of bolts don't over thirty
percent (30%).
4) The deflection of loaded point don't over the
initial deflection for fifteen percent (15%) .
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Radial Fatigue Tester

Load: 19391N
Cycles: 1,000,000times
Tire: 215/65R16
Tire pressure: 450kPa

1) No fatigue crack visible

2 No pressure loss attributable to wheel defect.

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Keep in mind

One Week later

Six months later

Jack
introduced AL
Alloy Wheel
to us and

Do you know AL
Wheel ?
How about the Mfg
process ?

Three months later

One year later

It seems
someone
introduced AL
Alloy Wheel to
us and

???

There are three typical tests for AL Alloy Wheel

There are many subjects included in AL Alloy Wheel
process
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Thank you for your

attention !

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